Use of a wax-modified, air rectified asphalt in built up roofing asphalt compositions

ABSTRACT

A composition and method for making a heat stable, low application temperature Built Up Roofing Asphalt (BURA) is provided. The composition comprises a wax-modified, air rectified asphalt conforming to Type 3 BURA and, in some embodiments, Type 4 BURA specifications.

RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional applicationSer. No. 14/944,374, filed on Nov. 18, 2015, which claims priority fromU.S. Provisional Application No. 62/082,683, filed on Nov. 21, 2014, theentire disclosures of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to asphalt roofing products,including asphalt for Built Up Roofing Asphalt (BURA) compositions.Particularly, the present disclosure relates to methods and compositionsfor producing a wax-modified, air rectified asphalt that meets the ASTMspecifications for Type 3 BURA and, in some embodiments, Type 4 BURA.The wax-modified, air rectified asphalt disclosed herein may be appliedat lower temperatures than conventional BURA compositions.

BACKGROUND

The Equiviscous Temperature (EVT) signifies the temperature needed toachieve the proper viscosity for proper application in the field. Inorder to achieve this temperature at application, the asphalt must beheated to an elevated temperature in a kettle prior to transport to arooftop. It is desirable to minimize both the kettle temperature and theEVT to the extent possible, while still maintaining the desired heatstability, viscosity, and ductility for a BURA composition.

SUMMARY

Various exemplary embodiments of the present invention are directed to aheat stable, low application temperature, built-up roofing asphalt(BURA).

In some exemplary embodiments, a BURA composition is disclosed. The BURAcomposition includes an air rectified asphalt and a wax additive. TheBURA composition has an equiviscous temperature (EVT) of from about 340°F. to about 390° F. for mopping applications and from about 380° F. toabout 430° F. for mechanical applications. This is between about 50° F.and 83° F. lower than conventional BURA application temperatures.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of this invention will be apparent upon consideration ofthe following detailed disclosure of the invention, especially whentaken in conjunction with the accompanying drawings wherein:

FIG. 1 is a graph depicting a Penetration Index of less than 2, based onthe definition provided by the Eurobitume Technical Committee Task Forcein 2011.

DETAILED DESCRIPTION OF THE DISCLOSURE

Numerical ranges as used herein are intended to include every number andsubset of numbers within that range, whether specifically disclosed ornot. Further, these numerical ranges should be construed as providingsupport for a claim directed to any number or subset of numbers in thatrange. For example, a disclosure of from 1 to 10 should be construed assupporting a range of from 2 to 8, from 3 to 7, from 5 to 6, from 1 to9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.

All references to singular characteristics or limitations of the presentdisclosure shall include the corresponding plural characteristic orlimitation, and vice versa, unless otherwise specified or clearlyimplied to the contrary by the context in which the reference is made.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methodsand materials are described herein. All references cited herein,including published or corresponding U.S. or foreign patentapplications, issued U.S. or foreign patents, or any other references,are each incorporated by reference in their entireties, including alldata, tables, figures, and text presented in the cited references. Inthe drawings, the thickness of the lines, layers, and regions may beexaggerated for clarity. It is to be noted that like numbers foundthroughout the figures denote like elements.

A heat stable, low application temperature, built-up roofing asphalt(BURA) composition is described in detail herein. In some exemplaryembodiments, the inventive composition includes an air rectified asphaltand a wax additive to meet the ASTM D 312 specifications for Type 3BURA, and in some embodiments, Type 4 BURA. Further, the applicationtemperature of the BURA composition disclosed herein is about 50° F. and83° F. lower than conventional BURA application temperatures.

U.S. Pat. No. 4,554,023, incorporated herein by reference in itsentirety, discloses the use of a bis-stearoylamide additive to reducethe viscosity of an asphalt to a viscosity desired for an ultimateblend. BURA compositions in accordance with this present invention mayinclude any combination or sub combination of the features disclosed bythe present application and U.S. Pat. No. 4,554,023.

U.S. Pat. Nos. 7,857,904, 7,951,239, 7,951,240, and 8,753,442 eachdisclose a method for producing coating asphalts. U.S. Pat. Nos.7,857,904, 7,951,239, 7,951,240, and 8,753,442 are each incorporatedherein by reference in their entirety. The methods include partially airblowing the paving grade asphalt feedstock to lower its penetrationvalue and raise its softening point. A wax is then added to thepartially blown asphalt to further raise its softening point to a pointthat is within the desired range for coating asphalt. This processadditionally incorporates a blowing catalyst, such as phosphoric acid,to further soften the asphalt. BURA compositions in accordance with thispresent invention may include any combination or sub combination of thefeatures disclosed by the present application and U.S. Pat. Nos.7,857,904, 7,951,239, 7,951,240, and 8,753,442.

U.S. Patent Application Ser. No. 61/953,413, incorporated herein byreference in its entirety, discloses methods and compositions forproducing BURA and coating asphalt compositions from non-coating gradeasphalts, such as paving-grade asphalts. The built up roofing asphaltcomposition incorporates an ester additive, such as a vegetable oil,fat, or plasticizer to over blown paving asphalt. BURA compositions inaccordance with this present invention may include any combination orsub combination of the features disclosed by the present application andU.S. Patent Application Ser. No. 61/953,413.

Definitions

As used herein, unless otherwise specified, the term “asphalt” is meantto include asphalts produced from petroleum refining, including residuafrom atmospheric distillation, from vacuum distillation, from solventde-asphalting units, and from recycled asphalt or petroleum productstreams, such as re-refined motor oil bottoms. Mixtures of differentasphalts may also be used. The general inventive concepts may also beused with natural bitumen, such as the products extracted from the oilsands in Alberta or asphalts derived from oil sands by various refineryprocesses.

As used herein, unless otherwise specified, the term “BURA” meansasphalt that is suitable for use as built up roofing asphalt accordingto the four types defined by ASTM D 312, displayed below in Table 1.

TABLE 1 Four Types of BURA According to ASTM D 312 TYPE 1 TYPE 2 TYPE 3TYPE 4 Property Min Max Min Max Min Max Min Max Softening point 57 66 7080 85 96 99 107 ° C. (° F.) (135) (151) (158) (176) (185) (205) (210)(225) Flash Point, 260 — 260 — 260 — 260 — ° C. (° F.) (500) (500) (500)(500) Penetration Units: (dmm) At 0° C. 3 6 6 6 (32° F.) At 25° C. 18 6018 40 15 35 12 25 (77° F.) At 46° C. 90 180 — 100 — 90 — 75 (115° F.)Ductility at 10.0 — 3.0 — 2.5 — 1.5 — 25° C. Solubility in 99 — 99 — 99— 99 — trichloro- ethylene %

The general inventive concepts herein relate to an asphalt compositionthat meets the properties listed in Table 1 for classification as Type 3BURA, and in some embodiments, Type 4 BURA.

The properties of the disclosed asphalt compositions may be measured byany suitable test known and accepted in the art. In the descriptionprovided herein, the asphalt properties are measured as follows:softening point or “SP” by ASTM D36; penetration or “pen” by ASTM D5 runat 25° C.; melt viscosity or “visc” by ASTM D4402; durability by ASTMD4798; flashpoint by ASTM D92; stain index by ASTM D2746; and stabilityby ASTM D3791 modified to run at oven temperature of 260° C. for up to 5days or similar test procedure.

Any suitable asphalt(s) may be used in accordance with the BURAcompositions disclosed herein. For example, paving asphalts which meetthe PG64-22 specifications (AASHTO M320) may be used, especially thosemeeting or exceeding the first number, 64, which is the average sevenday maximum pavement temperature performance test and is based onrheological properties such as dynamic shear. Paving asphalts weretraditionally graded by viscosity, and a common asphalt that is similarto the PG64-22 grade and usable in this method is the AC20 grade (ASTMD3381). Other examples of paving asphalts that may be suitable includePG67-22, PG-70-22, PG58-22, PG70-16, PG70-10, PG67-10, pen grade 40-50,pen grade 60-70, pen grade 85-100, pen grade 120-150, AR4000, AR8000,and AC30 grade. Additionally softer asphalts, commonly called roofersflux, as well as harder asphalts from solvent deasphalting processes canboth be used in blends or with various paving asphalts to achieve thedesired BURA product.

Method of Making the Air Rectified, Wax-Modified BURA

The present disclosure is directed to a heat stable BURA composition. Insome exemplary embodiments, the inventive composition includes an airrectified asphalt and a wax additive to meet the ASTM D 312specifications for Type 3 BURA and, in some embodiments, Type 4 BURA.

As described in detail hereafter, the general inventive conceptsencompass the use of air rectified, as opposed to more fully oxidized,asphalt in a BURA composition. Eurobitume has defined air rectifiedasphalt by a Penetration Index threshold, and this definition hasgenerally been adopted in the field. The Penetration Index (PI) iscalculated based on the softening point and penetration of the asphalt.FIG. 1 shows the combination of softening point and penetration thatmeets the Eurobitume distinction for air rectified asphalt. Combinationsof softening point and penetration that lie below the curve in FIG. 1give PI's of less than 2, and thus meet the standard for air rectifiedasphalts. In contrast, combinations above the line give PI's of greaterthan 2, and are defined as more fully oxidized asphalts.

A conventional air blowing process involves the oxidation of an asphaltcomposition by bubbling or blowing oxygen-containing gas (for example,air, oxygen or an oxygen-inert gas mixture) through molten asphalt at anelevated temperature for a particular processing time, such as fromabout 1 hour to about 12 hours. The processing time depends on variousfactors, such as the type of asphalt feedstock used, the processingtemperature, the air flow rate, the design of the process equipment, andthe desired characteristics of the BURA composition to be produced. Theprocess involves loading the asphalt feedstock into a converter(oxidizer) at any suitable temperature, for example, a temperature offrom about 200° C. to about 230° C. Thereafter, the gas is bubbled orblown through the molten asphalt. The reaction produced by the blowingis exothermic and raises the temperature of the asphalt to any suitableblowing temperature, for example, a temperature of from about 250° C.about 265° C. The maximum temperature is usually controlled by awater-cooled jacket. In some exemplary embodiments, the process iscarried out at ambient pressure, although it can also be carried out atelevated pressure. In some exemplary embodiments, the process is carriedout in batches, although it can also be carried out continuously.

Thus, whereas oxidized asphalts are produced over a wide range ofsoftening points and penetrations, air rectified asphalts are blown fora shorter time than higher softening point products, and are oftenreferred to as “partially blown” or “semi-blown.”

The “target softening point range” is the range that meets the ASTMspecification for the BURA composition. For example, for Type 3 BURA,the target softening point range is from 185° F. to 205° F. based on theASTM D312 specification. The intermediate or first softening point thatresults from the partial blowing step to produce an air rectifiedasphalt is lower than the target softening point range. For example, thefirst softening point may be within a range of from about 140° F. toabout 175° F., depending on the particular grade of asphalt used anddepending on whether or not a catalyst is used during blowing. In someexemplary embodiments, the first softening point is within a range offrom about 145° F. to about 165° F. In some embodiments the firstsoftening point is about 164° F. In some exemplary embodiments, thefirst softening point is about 156° F. In some exemplary embodiments,the first softening point is about 145° F.

In some exemplary embodiments, a blowing catalyst may be added to theasphalt before or during the partial blowing process. Several catalystsmay be suitable for use in the air blowing process to either speed upthe reaction or to create a final product with a higher penetration. Ifan optional blowing catalyst is used, any type of blowing catalyst ormixture of blowing catalysts may be used. Common catalysts includeferric chloride and phosphoric acid

The blowing process generates flue gases, which generally may containhydrogen sulfide, sulfur oxides (SOX), organosulfur compounds,hydrocarbons, nitrogen oxides (NOX), carbon monoxide, and water. Whenferric chloride is used as a catalyst, the flue gases may also containhydrogen chloride. Prior to release into the atmosphere, the flue gasesare typically passed through a water-sealed knockout tank and thensubjected to an incineration process to control the emissions ofvolatile organic compounds (VOC's). In that process, the sulfurcompounds are oxidized to form sulfur oxides, and the carbon monoxide isoxidized to carbon dioxide. The energy used to incinerate these fumesand the emissions that remain after incineration both increase as theprocessing time increases.

In accordance with the process described herein, a wax is added to thefirst softening point product. By adding a wax, the softening point isincreased to the target softening point range while maintaining apenetration within the desired range. In other embodiments, the waxaddition may lower or raise the penetration as it increases thesoftening point. In the case of a wax addition that lowers thepenetration, the partial blowing step of the method would be stopped ata higher penetration value and hence lower softening point value. Inthat case, the wax addition step further lowers the penetration to asecond penetration that is within the target penetration range. In oneembodiment, the asphalt may be further blown after the wax additionand/or other additives may be added, provided the asphalt maintains therequirements of an “air rectified” asphalt.

Any type of wax, or a mixture of one or more different waxes capable offunctioning as described herein, may be used in the present method. Insome exemplary embodiments, the wax has a high congealing point or ahigh drop melt point of at least about 75° C., including at least about90° C., and including at least about 100° C. When referring to waxtesting, the term “melt point” is used to refer broadly to eithercongealing point or drop melt point, which are defined by ASTM D 938 inthe case of congealing point and ASTM D 3954 in the case of drop meltpoint. Wax may also be characterized by penetration or hardness (ASTM D5or ASTM D1321), density (ASTM D1505), viscosity (ASTM D4402 or ASTMD88), or acid value (ASTM D1386).

In accordance with the general inventive concepts, the wax may be afunctionalized wax, a synthetic wax, or a naturally occurring wax.Further, the wax may be oxidized or non-oxidized. Some examples ofsynthetic waxes that may be suitable include ethylene bis-stearamide wax(EBS), Fischer-Tropsch wax (FT), oxidized Fischer-Tropsch wax (FTO),polyolefin waxes such as polyethylene wax (PE), oxidized polyethylenewax (PEO), polypropylene wax, polypropylene/polyethylene wax, alcoholwax, silicone wax, petroleum waxes such as microcrystalline wax orparaffin, and other synthetic waxes. Some examples of functionalizedwaxes include amine waxes, amide waxes, ester waxes, carboxylic acidwaxes, and microcrystalline waxes.

Exemplary naturally occurring waxes may be those derived from a plant,animal or mineral. Examples of natural waxes include plant waxes such ascandelilla wax, carnauba wax, rice wax, Japan wax and jojoba oil, animalwaxes such as beeswax, lanolin and whale wax, and mineral waxes such asmontan wax, ozokerite and ceresin.

Certain types of waxes may be particularly effective for use with theBURA compositions disclosed herein. In some embodiments, the wax is aFischer-Tropsch wax with a melt point of greater than 100° C., and ahardness at 25° C. of 1 dmm or less. In other embodiments, the wax is apolyethylene wax with a melt point of greater than 100° C. up to about120° C., a hardness at 25° C. up to about to 4 dmm, a density of fromabout 0.91 to about 0.95 gm/cc, a viscosity of about 20 to about 450 cpsat 140° C., and a nil acid number. In other embodiments, the wax is anoxidized polyethylene wax with melt point of about 135 to about 140° C.,a hardness at 25° C. of <0.5 dmm, a viscosity of about 3600 to about4500 at 150° C., and acid number of 30. In other embodiments, the wax isan ethylene bis-stearamide wax with a melt point of about 135° C. toabout 145° C. and an acid number of 8.

Further, any suitable mixtures of different waxes may also be used. Forexample, the wax may include a blend of a Fischer-Tropsch wax and apolyethylene wax.

In accordance with the general inventive concepts, the wax may be addedin any suitable amount. In some exemplary embodiments, the wax is addedin an amount from about 1% to about 5% by weight, including from about1.5% to about 4.5% by weight, including from about 2.5% to about 3.5% byweight of the BURA composition.

Properties of the Air Rectified, Wax-Modified BURA Composition

In some exemplary embodiments, the air rectified, wax-modified asphaltprovides the inventive BURA composition a resistance to a phenomenonknown as “dropback.” Dropback is a phenomenon that occurs when asphaltis exposed to high temperatures for a prolonged period of time. Ingeneral, the higher the temperature, or the longer the asphalt isexposed to heat, the lower the softening point and higher thepenetration value may become. However, even after being exposed to heat(about 500° F.) for 5 hours, 24 hours, or more, the inventive BURAcomposition does not exhibit a significant change in softening point orpenetration level. In some exemplary embodiments, the BURA compositionsaverage a loss of about 1° F. softening point after 5 hours at 500° F.and a gain of about 1° F. softening point after 24 hours at 500° F.

As discussed throughout the present disclosure, the inventive conceptsrelate to a BURA composition comprising air rectified, as opposed tomore fully oxidized, asphalt. The Equiviscous Temperature (EVT) is usedto determine the temperature to which the asphalt needs to be heated inorder to achieve proper application. The EVT is evaluated based on ASTMD 4402 standards. For mopping application, a temperature is needed thatachieves an asphalt viscosity of 125 cps. For mechanical application, atemperature is needed that achieves an asphalt viscosity of 75 cps. TheBURA composition disclosed herein has an application temperature that isbetween about 50° F. and 83° F. lower than typical conventional BURAapplication temperatures. In some exemplary embodiments, the BURAcomposition has an equiviscous temperature (EVT) of from about 340° F.to about 390° F. for mopping applications and from about 380° F. toabout 430° F. for mechanical applications. In some exemplaryembodiments, the BURA composition disclosed herein provides an averagedecrease in EVT of about 59° F. for mopping and about 45° F. formechanical applications compared to typical conventional BURAcompositions. In some exemplary embodiments, the BURA compositiondisclosed herein provides an average decrease in EVT of about 67° F. formopping and about 83° F. for mechanical applications compared toconventional BURA compositions.

The general inventive concepts have been described above bothgenerically and with regard to various exemplary embodiments. Althoughthe general inventive concepts have been set forth in what is believedto be exemplary illustrative embodiments, a wide variety of alternativesknown to those of skill in the art can be selected within the genericdisclosure. The general inventive concepts are not otherwise limited,except for the recitation of the claims set forth below.

As used in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. To theextent that the term “includes” or “including” is used in thespecification or the claims, it is intended to be inclusive in a mannersimilar to the term “comprising” as that term is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “or” is employed (e.g., A or B) it is intended to mean “Aor B or both.” When the applicants intend to indicate “only A or B butnot both” then the term “only A or B but not both” will be employed.Thus, use of the term “or” herein is the inclusive, and not theexclusive use. Also, to the extent that the terms “in” or “into” areused in the specification or the claims, it is intended to additionallymean “on” or “onto.” Furthermore, to the extent the term “connect” isused in the specification or claims, it is intended to mean not only“directly connected to,” but also “indirectly connected to” such asconnected through another component or components.

Unless otherwise indicated herein, all sub-embodiments and optionalembodiments are respective sub-embodiments and optional embodiments toall embodiments described herein. While the present application has beenillustrated by the description of embodiments thereof, and while theembodiments have been described in considerable detail, it is not theintention of the applicants to restrict or in any way limit the scope ofthe appended claims to such detail. Additional advantages andmodifications will readily appear to those skilled in the art.Therefore, the application, in its broader aspects, is not limited tothe specific details, the representative process, and illustrativeexamples shown and described. Accordingly, departures may be made fromsuch details without departing from the spirit or scope of theapplicant's general disclosure herein.

1-13. (canceled)
 14. An asphalt composition comprising: an air rectifiedasphalt blown to a first softening point from about 140° F. to about175° F.; and a wax additive, wherein the additive has a melt pointhigher than about 100° C.; wherein the asphalt composition has apenetration at 25° C. of 12 dmm to 35 dmm.
 15. The asphalt compositionof claim 14, wherein the asphalt composition has an equiviscoustemperature (EVT) of from about 340° F. to about 390° F. for moppingapplications and from about 380° F. to about 430° F. for mechanicalapplications.
 16. The asphalt composition of claim 14, wherein the airrectified asphalt is blown to a first softening point that is at leastabout 145° F.
 17. The asphalt composition of claim 14, wherein the airrectified asphalt is blown to a first softening point from about 145° F.to about 165° F.
 18. The asphalt composition of claim 14, wherein theair rectified asphalt is blown to a first softening point that is atleast about 156° F.
 19. The asphalt composition of claim 14, wherein theair rectified asphalt is blown to a first softening point of about 164°F.
 20. The asphalt composition of claim 14, wherein the wax additivecomprises from about 1.5% to about 4.5% based on the weight of the totalasphalt composition.
 21. The asphalt composition of claim 14, whereinthe wax additive comprises one or more of a functionalized wax, asynthetic wax, or a naturally occurring wax.
 22. The asphalt compositionof claim 14, wherein the wax additive comprises a synthetic wax selectedfrom ethylene bis-stearamide wax (EBS), Fischer-Tropsch wax (FT),oxidized Fischer-Tropsch wax (FTO), polyolefin wax, polyethylene wax(PE), oxidized polyethylene wax (PEO), polypropylene wax,polypropylene/polyethylene wax, alcohol wax, silicone wax, petroleumwax, microcrystalline wax, or paraffin.
 23. The asphalt composition ofclaim 22, wherein the wax additive comprises one or more of aFischer-Tropsch wax, a polyethylene wax, and an ethylene bis-stearamidewax.
 24. The asphalt composition of claim 14, wherein the wax additivecomprises a functionalized wax selected from amine waxes, amide waxes,ester waxes, carboxylic acid waxes, and microcrystalline waxes.
 25. Theasphalt composition of claim 14, wherein the wax additive comprises anaturally occurring wax derived from a plant, animal or mineral.
 26. Theasphalt composition of claim 25, wherein the naturally occurring wax isselected from candelilla wax, carnauba wax, rice wax, Japan wax, jojobaoil, beeswax, lanolin whale wax, montan wax, ozokerite and ceresin. 27.The asphalt composition of claim 14, wherein the asphalt composition hasa minimum solubility in trichloroethylene of 99%.
 28. The asphaltcomposition of claim 14, wherein the asphalt composition has apenetration at 25° C. of 15 dmm to 35 dmm.
 29. The asphalt compositionof claim 14, wherein the asphalt composition has a penetration at 25° C.of 12 dmm to 25 dmm.
 30. An asphalt composition comprising: an airrectified asphalt; and a wax additive, wherein the additive has a meltpoint higher than about 100° C.; wherein the asphalt composition has anequiviscous temperature (EVT) of from about 340° F. to about 390° F. formopping applications and from about 380° F. to about 430° F. formechanical applications.
 31. The asphalt composition of claim 30,wherein the air rectified asphalt is blown to a first softening pointfrom about 140° F. to about 175° F.
 32. The asphalt composition of claim30, wherein the air rectified asphalt does not include a blowingcatalyst.
 33. The asphalt composition of claim 30, wherein the asphaltcomposition has a penetration at 25° C. of 12 dmm to 35 dmm.